Kohler 8.5 & 12RES Installation Manual - Apprep.com

Installation Residential/Commercial Generator Sets

Models:

8.5RES 12RES Controller: Advanced Digital Control

TP-6328 5/04

Table of Contents Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I

Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Section 2 Installation 2.1 2.2 2.3 2.4

...................................................................... General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1 Exhaust Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2 Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2 Fuel Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3 Fuel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1 AC Load Lead Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3 Remote Start Connection (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.4 Continuous Power Mode Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.6 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1 Common Fault and Run Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.2 Carburetor Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 Prestart Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 Voltage and Frequency Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10.1 Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10.2 Frequency Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 6 6 6 7 7 7 8 10 10 10 11 11 12 14 14 14 15 16 16 17 17 18 18

Section 3 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.1 Specification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.2 Controller Wiring Diagram Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-4

TP-6328 5/04

Table of Contents

Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS. This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Accidental Starting WARNING

Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Battery WARNING

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

TP-6328 5/04

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Safety Precautions and Instructions

I

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

II


Engine Backfire/Flash Fire

Exhaust System WARNING

WARNING

Fire. Can cause severe injury or death.

Carbon monoxide. Can cause severe fainting, or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

The exhaust system must be leakproof and routinely inspected.

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.

Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.

nausea,

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following: D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

TP-6328 5/04

Fuel System WARNING

Hazardous Noise CAUTION

Explosive fuel vapors. Can cause severe injury or death.

Hazardous noise. Can cause hearing loss.

Use extreme care when handling, storing, and using fuels.

Never operate the generator set without a muffler or with a faulty exhaust system.

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

TP-6328 5/04

WARNING

Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Electrical Shock DANGER

Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure.

WARNING

Hazardous voltage. Moving rotor. Can cause severe injury or death.

Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

CAUTION

Welding the generator set. Can cause severe electrical equipment damage. Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM). Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Operate the generator set only when all guards and electrical enclosures are in place.


III

Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location. Installing the battery charger. Hazardous voltage can cause severe injury or death. An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances. Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

IV


Heavy Equipment WARNING

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.

Moving Parts WARNING

Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.

WARNING

Hot Parts WARNING

Rotating parts. Can cause severe injury or death. Operate the generator set only when all guards, screens, and covers are in place.

Hot engine and exhaust system. Can cause severe injury or death.

WARNING

Do not work on the generator set until it cools. Servicing the generator. Hot parts can cause severe injury or death. Avoid touching the generator set field or exciter armature. When shorted, the generator set field and exciter armature become hot enough to cause severe burns. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.

Airborne particles. Can cause severe blindness.

injury

or

Wear protective goggles and clothing when using power tools, hand tools, or compressed air. Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

TP-6328 5/04

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

Notice

NOTICE Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground.

NOTICE This generator set has been rewired from its nameplate voltage to

246242

NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.

TP-6328 5/04


V

Notes

VI


TP-6328 5/04

Section 1 Introduction This manual provides installation instructions for model 8.5RES and 12RES generator sets equipped with the Kohlerr Advanced Digital Control (ADC 2100). Refer to TP-6331, Operation Manual, for generator set operating instructions.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

The generator set is approved for use in stationary applications in locations served by a reliable utility power source.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual.

Have an authorized distributor/dealer install the generator set outdoors according to the instructions in this manual. The generator set installation must comply with the National Electrical Code (NEC) and local code requirements. Do not install this generator set indoors.

1

2

3

4

5

6

See Figure 1-1 for generator set component locations.

7

19

20

21

8 22 25 9 10

18

24 23

11

17 11

16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

15

14

Enclosure Silencer Oil check Oil fill Air cleaner Spark plug locations (both sides) Controller Generator set master switch (RUN\OFF/RESET\AUTO) Nameplate Line circuit breaker Air intake vents Engine starting battery location Oil drain hose

Figure 1-1

TP-6328 5/04

13

12

ADV-6823-A

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Oil drain valve Oil filter Alternator cooling air intake Exhaust outlet Spark arrestor DSAM leads Multi-fuel block Gas regulator assembly Fuel solenoid valve Battery charger Ground stud (GND) Relay board

Generator Set Component Locations

Section 1 Introduction

1

Service Assistance For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading

Generators—Electric D Visit

the Kohler Power Systems website at KohlerPowerSystems.com

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents included with the product D Call toll free in the US and Canada 1-800-544-2444 D Outside the US and Canada, call the nearest regional

office Headquarters Europe, Middle East, Africa (EMEA) Kohler Power Systems ZI Senia 122 12, rue des Hauts Flouviers 94517 Thiais Cedex France Phone: (33) 1 41 735500 Fax: (33) 1 41 735501

China North China Regional Office, Beijing Phone: (86) 10 6518 7950 (86) 10 6518 7951 (86) 10 6518 7952 Fax: (86) 10 6518 7955 East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550 India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) 80 3366208 (91) 80 3366231 Fax: (91) 80 3315972 Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727 Latin America Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 264-6422 Fax: (65) 264-6455

2

Section 1 Introduction

TP-6328 5/04

Section 2 Installation 2.1 General

2.3 Generator Set Inspection

Have an authorized distributor/dealer install the generator set outdoors according to the instructions in this manual. The generator set installation must comply with the National Electrical Code (NEC) and local code requirements. Do not install this generator set indoors.

Complete a thorough inspection of the generator set. Check for the following:

Use the specifications provided here only in the initial planning. Use the generator set and transfer switch spec sheets, dimension drawings, and wiring diagrams for installation.

2.2 Lifting WARNING

1. Inspect the generator set for loose or damaged parts or wires. Repair or tighten any loose parts before installation. 2. Check the engine oil. Fill, if necessary, with the recommended viscosity and grade of oil. Use synthetic oil, API (American Petroleum Institute) Service Class SG or higher. See TPTPS-6331, Operation Manual, for additional information.

2.4 Location and Mounting See Figure 2-1 for the generator set dimensions and fuel and electric inlet locations. The drawing dimensions are shown in millimeters, with inches in brackets.

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.

The generator set weighs approximately 186 kg (410 lb.). Use lifting bars inserted through the holes in the skid to lift the unit. See Figure 2-1 for lifting hole locations.

TP-6328 5/04

Install the generator set outdoors. Provide the minimum clearance around the generator set shown in Figure 2-2. Locate the generator set so that the hot exhaust does not blow on plants or other combustible materials. Do not install the generator set where exhaust gas could accumulate and seep inside or be drawn into a potentially occupied building. The generator set is shipped on a plastic mounting pad. Prepare a flat, level mounting area covered with a weed barrier and gravel as shown in Figure 2-2. Set the plastic mounting pad directly on the gravel. Do not install the mounting pad directly on grass.

Section 2 Installation

3

Note: Dimensions in [ ] are in inch equivalents.

Figure 2-1

4

Generator Set Mounting Details and Dimensions, ADV-6823A-C


TP-6328 5/04

Figure 2-2

TP-6328 5/04

Generator Set Clearances, ADV-6823B-C


5

2.4.1

Exhaust Requirements

2.4.2

WARNING

Carbon monoxide. Can cause severe fainting, or death.

The generator set requires correct air flow for cooling and combustion. The inlet and outlet openings in the sound enclosure provide the cooling and combustion air. Figure 2-4 shows the locations of the cooling air intake and exhaust vents. Inspect the air inlet and outlet openings inside and outside the housing to ensure that the air flow is not blocked.

nausea,

The exhaust system must be leakproof and routinely inspected.

The exhaust system is complete for generator sets installed outdoors. Do not install this generator set indoors. Figure 2-3 gives the exhaust flow and temperature at rated load. The engine exhaust mixes with the generator set cooling air at the exhaust end of the enclosure. Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials. Maintain the clearances shown in Figure 2-2. 60 Hz

3

Figure 2-4

Cooling Air Requirements

8.5RES 60 Hz

2.7 (96)

3.8 (135)

3.2 (113)

Engine exhaust temperature at rated kW, dry exhaust, _C (_F)

816 (1500)

Exhaust gas exiting the enclosure at rated kW, _C (_F)

316 (600)

12RES

50 Hz

60 Hz

50 Hz

Cooling air, m3/min. (cfm)

26.9 (950) 22.4 (790) 26.9 (950) 22.4 (790)

Total inlet air requirement, m3/min. (cfm)

27.8 (980) 23.2 (820) 28.0 (990) 23.4 (825)

Combustion air, m3/min. (cfm)

0.94 (33.4) 0.8 (28.0)

2.5 Power Supply

3.3 (115)

12RES

tp6195

Cooling Air Intake and Exhaust

Figure 2-5

8.5RES

Exhaust Flow and Temperature

2 1. Exhaust outlet 2. Alternator air intake (both sides) 3. Engine air intake

50 Hz

Exhaust flow at rated kW, m3/min. (cfm)

Figure 2-3

3

1

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.

Exhaust System

Air Requirements

1.1 (39.2)

0.9 (32.6)

Cooling Air Requirements

Power must be supplied to the generator set location for the battery charger and the optional carburetor heater. Install a 120-VAC receptacle powered from the essential loads panel. Figure 2-6 lists the power requirements for the battery charger and accessories. The installation of the receptacle must comply with the NEC and local code requirements. Power Requirement, Max. Watts

Amps

192

1.60

38

0.32

Battery heater

110

0.92

Total with accessories

340

2.84

Equipment Battery charger Carburetor heater

Figure 2-6

6


Volts 120

120

Power Requirements

TP-6328 5/04

2.6 Fuel System The generator set operates using natural gas or LP vapor fuel. The generator set is CARB- and EPA-certified for both natural gas and LP vapor fuels.

Fuel System Fuel types

Natural Gas or LP Vapor

Fuel supply inlet

1/2 NPT

Fuel supply pressure, kPa (in. H2O)

Nominal Fuel Rating,

The fuel system installation must comply with the NEC and local codes.

2.6.1

Fuel Supply

Because of variable climates and geographical considerations, contact the local fuel supplier for fuel system planning and installation. Figure 2-7 lists the recommended fuel ratings for natural gas and LP vapor fuels. Verify that the output pressure from the primary gas utility (or LP tank) pressure regulator is 1.7--2.7 kPa (7--11 in. water column) and that the utility gas meter flow rate is sufficient to supply the generator set plus all other gas-consuming appliances. Figure 2-8 shows the flow rate required for the generator set and Figure 2-9 shows the fuel consumption. Contact the fuel supplier for flow rate information or a gas meter upgrade. Figure 2-1 shows the location of the fuel inlet connection. Use flexible sections to prevent fuel line breakage caused by vibration. Remove the housing end panel and hold the fuel solenoid valve with a wrench when tightening the fuel connections. Protect all fuel lines from machinery or equipment contact, adverse weather conditions, and environmental damage.

2.6.2

Fuel Pipe Size

Ensure that the natural gas pipe size and length meet the specifications in Figure 2-10. Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet. Add 2.4 m (8 ft.) to the measured length for each 90 degree elbow. Compare the pipe size and length with the chart in Figure 2-10. If the piping is longer than the maximum length shown for that size, replace it with the specified size before proceeding.

1.7--2.7 (7-11)

Btu/ft3

Natural gas

1000

LP vapor

2500

Figure 2-7

Fuel Supply

Model

Gas Flow Rate, Btu/hr.

8.5RES

132,000

12RES

202,000

Figure 2-8

Natural Gas Flow Rate (Btu/hr.)

Fuel Consumption Consumption, m3/hr. (cfh)

8.5RES 60 Hz

12RES

50 Hz

60 Hz

50 Hz

Natural gas at % load 100%

3.7 (132)

3.3 (118)

5.9 (209)

4.9 (175)

75%

3.2 (113)

2.9 (101)

4.8 (168)

4.0 (141)

50%

2.6 (93)

2.3 (83)

3.6 (127)

3.0 (106)

25%

2.2 (77)

1.9 (69)

2.4 (85)

2.0 (71)

LP vapor at % load 100%

2.0 (72)

1.7 (61)

3.1 (108)

2.5 (89)

75%

1.3 (45)

1.1 (38)

2.5 (87)

2.0 (72)

50%

1.0 (36)

0.9 (31)

1.9 (65)

1.5 (53)

25%

0.8 (29)

0.7 (25)

1.2 (44)

1.0 (36)

LP vapor conversion factors: 8.58 ft3 = 1 lb. 36.39 ft3 = 1 gal.

Figure 2-9

Fuel Consumption Maximum Pipe Length m (ft.)

Pipe Size 3/4 in. NPT 1 in. NPT 1 1/4 in. NPT

8.5RES 18.3

(60)

12RES 9.2

(30)

61 (200)

30 (100)

91.5 (300)

68.6 (225)

Figure 2-10 Maximum Natural Gas Pipe Length

Contact the local LP provider for LP installation information.

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7

2.6.3

Fuel Conversion

The multi-fuel system allows conversion from natural gas to LP vapor (or vice-versa) in the field while maintaining emissions-standard compliance. A trained technician or authorized distributor/dealer can convert the fuel system.

WARNING

Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

WARNING

Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels.

8


Two fuel connections on the fuel block allow fieldconversion between natural gas and LP vapor. The fuel metering valves are factory-set and sealed to comply with applicable emission standards and to provide the best possible hot and cold starting. Note: Do not adjust the factory-sealed fuel-metering adjustments on the fuel block. Changing the fuel-metering adjustments may violate federal or state laws. Use the following procedure to convert from natural gas to LP vapor, moving the fuel connection from the natural gas to the LP port, plugging the natural gas port, and connecting the leads to the digital spark advance module (DSAM). See Figure 2-11 for the fuel system component locations. Fuel Conversion Procedure 1. Place the generator set master switch in the OFF position. 2. Disconnect the power to the battery charger. 3. Disconnect the generator set engine starting battery, negative (--) lead first. 4. Turn off the fuel supply. 5. Remove the hose clamp and fuel hose from the hose fitting in the fuel block. See Figure 2-12. 6. Remove the hose fitting from the natural gas outlet port in the fuel block. See Figure 2-12. 7. Remove the plug from the LP port in the fuel block. See Figure 2-12. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install the plug into the natural gas outlet port. 8. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant to the threads, and install the fitting into the LP port. Note: Do not adjust the fuel metering valves.

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1

9. Slide the hose onto the hose fitting and secure it with the clamp.

2

10. For the 12RES only: Connect the digital sparkadvance module (DSAM) leads together for natural gas. (Disconnect leads for LP.) See Figure 2-13. 11. Connect and turn on the new fuel supply. 3

12. Check that the generator set master switch is in the OFF position. 13. Reconnect the generator set engine starting battery leads, negative (--) lead last. 14. Reconnect power to the battery charger. 15. Start the generator set by moving the generator set master switch to the RUN position.

GM29253

16. Check for leaks using a gas leak detector.

1. DSAM connector location 2. Fuel block 3. Fuel inlet, 1/2 in. NPT female

17. Move the generator set master switch to the OFF/RESET position to shut down the generator set.

Figure 2-11 Fuel System Locations, Air Inlet Side

To convert from LP vapor to natural gas, follow the same fuel conversion procedure, moving the hose fitting to the natural gas port and plugging the LP port. For the 12RES model, disconnect the DSAM leads for LP vapor. See Figure 2-13.

1 5

2

4

3

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1. 2. 3. 4. 5.

Fuel block Fuel metering valves—factory-sealed, do not adjust Fuel inlet, 1/2 in. NPT Hose fitting Plug

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1

Figure 2-12 Fuel Block Connections, Natural Gas System Shown

1. DSAM leads: connect for natural gas, disconnect for LP.

Figure 2-13 Digital Spark Advance Module (DSAM) Leads (located in generator set air intake area)

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9

2.7 Electrical Connections WARNING

Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

NOTICE Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.

Have an authorized distributor/dealer or a licensed electrician make the following electrical connections. Verify that the electrical installation complies with the National Electrical Code (NEC) and all applicable local codes. Ground the generator set from the GRD terminal inside the controller compartment according to applicable codes. See Figure 2-14.

2.7.1

through flexible conduit directly to the AC circuit breaker box. See Figure 2-1 for the recommended electrical inlet location. Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas. See Figure 2-14 and Section 3, Wiring Diagrams, for the generator set electrical connections. Make the following AC connections: 1. Connect the output leads going to the transfer switch (L1/L2 black leads) to the AC circuit breaker load side. 2. Connect the L0 white leads from the ATS and the main panel to the neutral terminal. 3. Connect the green lead to the ground terminal (labeled GRD). Verify that the electrical installation complies with the National Electrical Code (NEC) and all applicable local codes.

2.7.2

Grounding

Ground the generator set. The grounding method must comply with NEC and local codes. Connect the gounding strap to the generator set ground lug, terminal GND inside the controller compartment. Kohler generator sets are shipped with the generator neutral attached to the generator in the junction box. At installation, the neutral can be grounded at the generator set or lifted from the ground stud and isolated if the installation requires an ungrounded neutral connection at the generator. The generator set will operate properly with the neutral either bonded to ground or isolated from ground at the generator. Various regulations and site configurations including the National Electrical Code (NEC), local codes, and the type of transfer switch used in the application determine the grounding of the neutral at the generator. NEC 2002 Section 250.20 is one example that has a very good explanation of the neutral grounding requirements for generators.

AC Load Lead Connections

Connect the AC output leads in the controller compartment to the AC circuit breaker. Route AC leads

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2.7.3

Remote Start Connection (optional)

Connect leads 3 and 4 from the ADC 2100 controller to the automatic transfer switch’s engine start terminals or to an optional remote start/stop switch. Route the engine start leads through separate conduit from the AC power and load leads. 1

Note: For most applications, it is not necessary to disconnect the continuous power mode jumper. The 8.5 and 12 RES generator sets are equipped with factory-installed battery chargers to prevent battery discharge. Use the following procedure to disconnect the jumper, if desired. Procedure to disconnect the continuous power mode jumper (optional).

2 3

1. Prevent the generator set from starting. a. Move the generator set master switch to the OFF/RESET position. Bottom of Controller Compartment

b. Disconnect power to the battery charger. c. Disconnect the generator set engine starting battery, negative (--) lead first.

1

2. Remove the controller from the generator set housing. a. Disconnect the engine wiring harness connector P1 plug (35-pin) from the controller. Disconnect the J15 and J16 connectors. See Figure 2-15.

2, 3

b. Remove the controller from the generator set housing in order to access back of controller. 3. Remove the controller’s back cover to access the jumper. GM29253A-F

1. Line circuit breaker 2. Ground terminal (GRD) 3. Neutral terminal (L0)

Figure 2-14 Field-Installed Wiring Connections

2.7.4

Continuous Power Mode Jumper

A jumper across controller pins P7-1 and P7-2 maintains power to the controller at all times. See Figure 2-15. Controllers are shipped with jumper connected for continuous power. The P7 connector has either 2 or 3 pins. Disconnecting the jumper or moving the jumper to pins P7-2 and P7-3 allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position. A remote start signal (from a transfer switch or a remote start/stop switch connected to controller leads 3 and 4) or moving the generator set master switch to the RUN position turns the controller back on.

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a. Note the labels on the three leads connected to generator set master switch for reconnection later. Disconnect the leads at the pink connectors. See Figure 2-15. b. Remove the cover screws and remove the controller’s back cover. See Figure 2-15. 4. Locate the P7 connector near the top of the controller. See Figure 2-15. Remove the jumper from pins 1 and 2 of the P7 connector. If the P7 connector has three pins, connect the jumper across pins 2 and 3 for storage. 5. Replace the controller’s back cover and secure the cover screws. 6. Reconnect the three pink connectors to the generator set master switch. 7. Reconnect the J15 and J16 connectors.


11

8. Reconnect the generator set engine starting battery, negative (--) lead last.

2.7.5

Battery WARNING

9. Reconnect power to the battery charger. 10. Place the generator set master switch in the AUTO position.

2

Sulfuric acid in batteries. Can cause severe injury or death.

1

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

WARNING

Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes. tp6195

5 1. 2. 3. 4. 5.

4

3

Engine wiring harness connector plug (P1) Continuous power mode jumper location (P7) J15 connector J16 connector Generator set master switch connectors

Figure 2-15 Advanced Digital Control Connections

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

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Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies).

1

2

EZ-273000-J

1. To positive (+) terminal on starter solenoid. 2. To ground (--) terminal on or near starter motor.

Figure 2-16 12-Volt Engine Electrical System Single Starter Motor Typical Battery Connection

1

GM29253

1. Engine starting battery location

Figure 2-17 Battery Location, Air Intake End Use a 12-volt battery with a minimum rating of 675 cold cranking amps at 0_F. The generator set uses a negative ground with a 12-volt engine electrical system. See Figure 2-16 for battery connections. Make sure that the battery is correctly connected and the terminals are tight. Note: The generator set will not start and circuit board damage may occur if the battery is connected in reverse. Figure 2-17 shows the location of the engine starting battery. Standard battery cables provide easy connection to the battery. Use the following procedure to install and connect the battery.

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Battery Installation Procedure 1. Ensure that the starting battery is fully charged before placing the battery in service. 2. Clean the battery posts and/or adapters if necessary. 3. Install the battery post adapters, if needed. 4. Place the battery in the housing. 5. Verify that the controller master switch is in the OFF position.


13

6. Connect the positive (+) lead to the engine starting battery.

Connect customer equipment to the relay board harness. Figure 2-19 lists the customer connections.

7. Connect the negative (--) lead to the engine starting battery.

The common fault relay is energized on a fault. The auxiliary run relay is energized when the generator set is running. Connect to each relay’s normally open or normally closed contacts depending on the application.

Refer to the generator set Operation Manual for battery maintenance instructions.

2.7.6

Battery Charger

A 6-amp battery charger is factory-installed in the battery compartment. The battery charger’s DC leads are factory-connected. The battery charger is required to keep the starting battery fully charged.

1 2

Plug the battery charger’s power cord into a 120 VAC receptacle on the load side of the system. Refer to the generator set Operation Manual for battery charger operation information.

2.8 Accessories Have accessories installed by an authorized distributor/ dealer or a licensed electrician. Follow the installation instructions provided with each kit. Use separate conduit for AC and DC leads to reduce the possibility of electrical interference. Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas. Verify that the electrical installation complies with the National Electrical Code (NEC) and all applicable local codes. See Section 3, Wiring Diagrams, for more information regarding generator set electrical connections.

2.8.1

Common Fault and Run Relay Board

The optional relay board provides two additional relays to control customer-provided equipment:

GM30414

1. Relay board 2. Relay board harness

Figure 2-18 Common Fault and Run Relay Board Harness Lead Number

Connector Pin Number

88

6

Common fault normally open

89

2

Common fault common

90

3

Common fault normally closed

91

4

Run relay normally open

92

1

Run relay common

93

5

Run relay normally closed

Connection

D Common fault relay D Auxiliary run relay

The optional relay board replaces the standard relay board. The relay board location is shown in Figure 2-18.

14


Figure 2-19 Common Fault and Run Relay Board Harness Connections

TP-6328 5/04

2.8.2

Carburetor Heater

An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0_C (32 _F). The carburetor heater prevents condensation and carburetor icing. The heater turns on when the temperature at the thermostat falls below approximately 4_C (40_F) and turns off when the temperature rises above approximately 16_C (60_F).

1

2

The heater requires a continuous source of 120 VAC power. The heater power cord and thermostat are located in the generator set housing air intake area/ battery compartment. See Figure 2-17. Plug the carburetor heater into an outlet that supplies continuous 120 VAC power. The heater thermostat is installed in the cord. Figure 2-21 shows the location of the thermostat on the power cord. Note: Do not place the heater thermostat inside the generator set engine compartment. The thermostat must be exposed to the ambient air. The thermostat will shut off power to the heater when the ambient temperature reaches approximately 60_F (16_C).

1

1. Thermostat 2. Connector 3. Heater

2

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1. Carburetor heater (air cleaner removed to show heater) 2. Carburetor heater power cord

Figure 2-20 Carburetor Heater

3

GM19463

Figure 2-21 Carburetor Heater with Thermostat

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15

2.9 Prestart Installation Check Review the entire installation section. Inspect all wiring and connections to verify that the generator set is ready for operation. Check all items in the following Prestart Checklist.

2.10 Voltage and Frequency Adjustments WARNING

Prestart Checklist Air Cleaner. Check that a clean air cleaner element is installed to prevent unfiltered air from entering the engine. Air Inlets. Check for clean and unobstructed air inlets. Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance. Exhaust System. Check for exhaust leaks and blockages. Check the muffler and piping condition. D Inspect the exhaust system components (exhaust

manifold, exhaust line, flexible exhaust, clamps, muffler, and outlet pipe) for cracks, leaks, and corrosion. Check for tight exhaust system connections. D Check for corroded or broken metal parts and replace

them as needed. D Check that the exhaust outlet is unobstructed.

Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick. Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.

Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

The controller’s adjustment mode allows adjustment of the output voltage and frequency, if necessary. Have adjustments performed by an authorized distributor/dealer or service technician. Note: A digital multimeter that measures voltage and frequency is required for these adjustments. Use a digital multimeter to check the output voltage and frequency. If the output voltage or frequency is not within specifications, use the ADC controller to adjust the output voltage and engine speed (frequency) while the generator set is running. The flowcharts in Figure 2-25 through Figure 2-27 outline the adjustment procedures. Note: Be sure to save your settings before exiting the configuration mode. Changes in voltage and speed adjustments are lost if they are not saved before the generator set shuts down. The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup if the changes have not been saved. Pressing the Select button when SAVE is displayed returns to the first parameter, voltage adjust (1P).

16


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output until the engine speed drops below the cut-in frequency set in step 7.

2.10.1 Voltage Adjustment Note: Refer to the flowcharts in Figure 2-25 through Figure 2-27 for instructions to adjust the voltage using the ADC controller. Voltage Adjustment Procedure 1. With the generator set off, connect a digital multimeter to the output leads or an electrical outlet on the load side of the generator set. Set the meter to measure AC voltage.

9. Reset the engine speed to the operating frequency (50 or 60 Hz) by adjusting the engine governor speed (parameter 4P). 10. Readjust the voltage stability (gain, parameter 2P), if necessary. 11. Readjust the voltage (parameter 1P), if necessary. 12. Stop the generator set.

2. Start the generator set by moving the generator set master switch to the RUN position.

2.10.2 Frequency Adjustment

3. Use the ADC controller to adjust the voltage (parameter 1P) until the output voltage reaches the desired value. See Figure 2-22 for the approximate change in voltage per step in parameter 1P.

The engine speed determines the generator output frequency; 60 Hz units operate at 3600 rpm and 50 Hz units run at 3000 rpm. Adjust the engine governor speed to change the output frequency using the following procedure.

Measured Voltage, V l VAC

Voltage Change per Step, VAC Coarse Adjust

Fine Adjust

85--132

5

0.5

180--251

7

0.7

Figure 2-22 Voltage Adjustment (approximate) 4. Adjust the voltage stability (gain, parameter 2P) to minimize light flicker. 5. Readjust the voltage, if necessary.

Note: Refer to the flowcharts in Figure 2-25 through Figure 2-27 for instructions to adjust the engine speed using the ADC controller. Frequency Adjustment Procedure 1. Attach a frequency meter to the AC output leads or an electrical outlet on the load side of the generator set. 2. Start and run the generator set until it reaches normal operating temperature (at least 10 minutes).

6. Set the multimeter to measure frequency. 7. Adjust the engine speed to the cut-in frequency shown in Figure 2-23 by adjusting the engine governor speed (parameter 4P). Frequency

Cut-In Frequency

60 Hz

57.5 Hz

50 Hz

47.5 Hz

Figure 2-23 Cut-In Frequencies 8. Adjust the volts/Hz (parameter 3P) until the voltage level measured by the multimeter begins to drop. When the volts/Hz is set correctly, the generator (as load is applied) attempts to maintain normal

TP-6328 5/04

3. Adjust the electronic governor speed (parameter 4P) to obtain a frequency reading of 60 Hz (or 50 Hz on 50 Hz models). Each step changes the engine speed about 3.6 RPM, which changes the output frequency about 0.06 Hz. 4. Check stability with the generator set running and with no load applied. If the generator set speed is unstable, hunts, or surges, adjust the governor stability (gain, parameter 5P) until the generator set becomes stable with no hunting or surging. (Increasing the gain slows the governor response.) 5. Check the frequency reading. Repeat steps 3 and 4 if necessary to obtain the rated frequency and stable operation.


17

2.11 Controller Configuration The controller configuration for each generator model is set at the factory and should not normally require changes. The controller’s configuration mode allows adjustment of the system parameters listed in this section. Use the instructions in this section to check the configuration after installation and change them to match the settings shown in Figure 2-24, if necessary. The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed. Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved. Follow the instructions in Figure 2-28 to enter the configuration mode while the engine is not running and then step through the following parameters. Use the up (∧) and down 〈∨) arrow buttons to select the appropriate setting for the application. Voltage/frequency setting (Uu). Select the system voltage and frequency from the table in Figure 2-24. Note: This parameter sets the nominal system voltage and frequency. To adjust the output (measured) voltage and frequency, see Section 2.10. Unit configuration (Uc). This parameter sets the generator set type: marine, standby, or mobile. The setting for the 8.5/12RES is Uc01, standby.

Advanced configuration mode (Adnc). The data input types, battery voltage, and communications setting can be changed in the advanced configuration mode. Press the up arrow button when Adnc is displayed to enter the advanced configuration mode. Engine data input types (Ed). This setting defines the type of senders used on the generator set engine. Use Ed05 for the 8.5/12RES. Battery voltage (Bt). This setting toggles between 12 and 24 VDC for the engine starting battery voltage. The 8.5/12RES uses a 12-volt battery, Bt12. Communications setting (Cn). This setting allows the user to set the controller for communication with optional meters, which are available for marine and mobile units only. The 8.5/12RES is factory-set for no CAN communications, Cn00. Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position.

2.12 Warranty Registration Complete the startup and installation checklists supplied with the startup notification form. Complete and sign the startup notification form and return copies to Kohler Co. and the distributor/dealer as instructed on the form.

Engine configuration (Ec). The engine configuration must match the generator set engine type. The engine configuration setting for the 8.5/12RES is Ec00. Parameter Unit’s system y voltage g and d frequency. f Unit configuration Engine type Engine data input types Battery voltage Communications

Setting Uu01 Uu06 Uc01 Ec00 Ed05 Bt12 Cn00

Definition Single phase, 60 Hz, 120/240 VAC Single phase, 50 Hz, 115/230 VAC 8.5/12 RES (standby) 8.5/12 RES Digital low coolant level, digital pressure, analog temp, with mag. pickup Engine starting battery voltage, 12 VDC No CAN communications

Figure 2-24 8.5/12RES Controller Configuration Parameters

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Output Voltage and Frequency Adjustment Mode:

Display :*

Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours.

x x x x

Hold:

x. x x

Wait about 5 seconds until the display changes from runtime hours to the program version number. Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode. (This is the controller “password.”)

1 P x x

The controller is now in the voltage coarse adjustment mode. Press: or

To raise or lower the voltage in large increments (approximately 5--7 volts per step).

To enter fine voltage adjustment mode.

or

1 P x x

1 P x x

To raise or lower the voltage in smaller increments (approximately 0.5--0.7 volts per step).

To enter coarse voltage stability (gain) adjustment mode.

2 P x x or

To raise or lower the voltage stability (gain) in large increments.

To enter fine voltage stability (gain) adjustment mode.

or

To raise or lower the voltage stability (gain) in smaller increments.

To enter volts/Hz adjustment mode.

or

2 P x x

3 P 0 x

To raise or lower the volts/Hz: 00=low; 09= high

Continued on Figure 2-26. * Shaded boxes show which character in the controller display changes for each adjustment. X in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.

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Figure 2-25 Output Voltage and Frequency Adjustments TP-6328 5/04


19

Continued from Figure 2-25:

Display : *

Press: To enter engine governor speed coarse adjustment mode. or

To raise or lower the engine speed in large increments.

To enter engine governor speed fine adjustment mode. or

5 P x x

To raise or lower the engine governor stability (gain) in large increments.

To enter engine governor stability (gain) fine adjustment mode.

or

4 P x x

To raise or lower the engine speed in smaller increments.

To enter engine governor stability (gain) coarse adjustment mode. or

4 P x x

5 P x x

To raise or lower the engine governor stability (gain) in smaller increments.

To enter SAVE mode. Go to Figure 2-27.

S AV E

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position. * Shaded boxes show which character in the controller display changes for each adjustment. X in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-model. Figure 2-26 Output Voltage and Frequency Adjustments, Continued

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There are 3 options when the display says SAVE: Press:

S AV E

To return to the first parameter, coarse voltage adjustment, to check or change settings before saving. See Figure 2-25.

1 P x x

To save changes.

Y E S

To discard changes without saving.

n o

or

or

“Yes”or “no” flashes when the up or down arrow is pressed and then the controller exits the configuration mode. The display returns to the runtime hours.

x x x x

Now move the master switch to OFF/RESET. Figure 2-27 Save Mode

TP-6328 5/04


21

Controller Configuration Mode: Hold the Select button:

Display: Move the generator set master switch to the RUN position. (The generator set engine will not start.)

.

Wait about 5 seconds until the display shows the program version number. (The number may be different than the one shown here.)

1 0 4

Press the down arrow key and then the up arrow key 3 times to enter the configuration mode. (This is the controller “password.”)

0

Uu 0 1

Now release the Select button. Press: or

To set the voltage/frequency setting to Uu01 for 60 Hz or Uu06 for 50 Hz models.

U u 0 1 60 Hz U u 0 6 50 Hz

To step to the next parameter, unit configuration Uc. or

To set the unit configuration setting to Uc01, if necessary.

Uc 0 1

To step to the next parameter, engine type Ec.

or

To set the engine type to Ec05, if necessary.

E c 0 5

To step to the next parameter, advanced configuration mode or save mode selection.

Ad n c

Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs, battery voltage, and communications. Press: To enter advanced configuration mode. Go to Figure 2-29.

E d 0 5

To proceed to the save mode without entering the advanced configuration mode. Go to Figure 2-30.

S AV E

or or

Note: Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed. Figure 2-28 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)

22


TP-6328 5/04

Pressing the up arrow key at the Adnc display (See Figure 2-28) puts you into the Advanced Configuration Mode. Press: or

To set the engine data input type to Ed05.

E d 0 5

To enter battery voltage selection mode.

or

To toggle between 12 and 24 VDC. Set this parameter to 12 VDC.

B t 1 2

To enter communications selection mode.

or

To set the communications parameter to Cn00.

C n 0 0

To enter SAVE mode. Go to Figure 2-30.

S AV E

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position. Figure 2-29 Advanced Configuration Mode (engine data input types, battery voltage, and engine communications)

There are 3 options when the display says SAVE: Press: To return to the first parameter, system voltage/frequency Uu, to check or change settings before saving. See Figure 2-28.

S AV E Uu 0 1

or To save changes.

Y E S

To discard changes without saving.

n o

or

“Yes”or “no” flashes when the up or down arrow is pressed and then the controller exits the configuration mode. The display returns to the runtime hours.

x x x x

Now move the master switch to OFF/RESET. * X in the runtime hours display above denotes any number from 0 to 9. Figure 2-30 Save Mode (after configuring generator set parameters)

TP-6328 5/04


23

Notes

24


TP-6328 5/04

Section 3 Wiring Diagrams 3.1 Specification Numbers At the time of print, this manual applied to the model numbers and specification (spec) numbers in Figure 3-1. On occasion, the manufacturer may provide this manual with units that are not listed below, such as when similar new specs are created prior to the updated reprint or in other cases when the manual is a suitable substitute for a manual under development. Model No.

Spec. No.

8.5RES

GM29253-GA1

12RES

GM29253-GA2

Figure 3-1

TP-6328 5/04

3.2 Controller Wiring Diagram Reference Figure 3-2 lists the wiring diagram numbers and locations.

Wiring Diagram Description Schematic Diagram Sheet 1 Sheet 2 Point-to-Point Wiring Diagram

Figure 3-2

Drawing Number

Page

ADV-6835A-B ADV-6835B-B

26 27

GM29358-C

28

Controller Wiring Diagrams

Generator Set Specification Numbers

Section 3 Wiring Diagrams

25

-

Figure 3-3 26

8.5/12RES Schematic Diagram, Single Phase, Sheet 1, ADV-6835A-E

Section 5 Diagrams and Drawings

TP-6328 5/04

Figure 3-4

TP-6328 5/04

8.5/12RES Schematic Diagram, Single Phase, Sheet 2, ADV-6835B-E


27

Figure 3-5

28

8.5/12RES Point-to-Point Wiring Diagram, Single Phase, GM29358-D


TP-6328 5/04

Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI

AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw. CEC cert.

ampere after bottom dead center alternating current analog to digital analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute (formerly American Standards Association, ASA) anticipatory only American Petroleum Institute approximate, approximately as required, as requested as supplied, as stated, as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator Battery Council International before dead center brake horsepower black (paint color), block (engine) block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius, centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate, certification, certified

TP-6328 5/04

cfh cfm CG CID CL cm CMOS

cubic feet per hour cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards Association CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung e. V. (also Deutsche Industrie Normenausschuss) DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DSAM digital spark-advance module DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems Association EIA Electronic Industries Association EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection Agency EPS emergency power system ER emergency relay ES engineering special, engineered special ESD electrostatic discharge

est. E-Stop etc. exh. ext. F fglass. FHM fl. oz. flex. freq. FS ft. ft. lbs. ft./min. g ga. gal. gen. genset GFI

estimated emergency stop et cetera (and so forth) exhaust external Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute gram gauge (meters, wire size) gallon generator generator set ground fault interrupter

GND, gov. gph gpm gr. GRD gr. wt. HxWxD HC HCHT HD HET

ground governor gallons per hour gallons per minute grade, gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temperature, high engine temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal/external input/output iron pipe

hex Hg HH HHC HP hr. HS hsg. HVAC HWT Hz IC ID IEC IEEE IMS in. in. H2O in. Hg in. lbs. Inc. ind. int. int./ext. I/O IP

Appendix A-1

ISO

International Organization for Standardization J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (210 bytes) kg kilogram kg/cm2 kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (106 when used with SI units), male m3 cubic meter m3/min. cubic meters per minute mA milliampere man. manual max. maximum MB megabyte (220 bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mΩ milliohm MOhm, MΩ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour A-2 Appendix

MS m/sec. MTBF MTBO mtg. MW mW µF N, norm. NA nat. gas NBS NC NEC NEMA

military standard meters per second mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal (power source) not available, not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., ∅ phase PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency) power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference

RH RHM rly. rms rnd. ROM rot. rpm RS RTV SAE

round head round head machine (screw) relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites, International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single--pole, double--throw SPST single--pole, single--throw spec, specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-6328 5/04

Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.

Steps for common hardware application: 1. Determine entry hole type: round or slotted. 2. Determine exit hole type: fixed female thread (weld nut), round, or slotted. For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or 1/2 inch in diameter or less. Hardware that is greater than 1/2 inch in diameter takes a standard nut and SAE washer. Hardware 1/2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See Figure 2.

Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications. See Appendix C, General Torque Specifications, and other torque specifications in the service literature.

3. Follow these SAE washer rules after determining exit hole type: a. Always use a washer between hardware and a slot.

Preferred Nut/Bolt Clearance 1

2

b. Always use a washer under a nut (see 2 above for exception). c. Use a washer under a bolt when the female thread is fixed (weld nut). 4. Refer to Figure 2, which depicts the preceding hardware configuration possibilities.

Unacceptable Nut/Bolt Clearance 3

2

1

3 G-585

1. 1/2 of bolt diameter 2. Min. 1 full thread beyond top of nut 3. Below top of nut

Figure 1

Acceptable Bolt Lengths 5 4

6

G-585

1. 2. 3. 4. 5. 6.

Cap screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock: up to 1/2 in. dia. hardware Weld nuts: above 1/2 in. dia. hardware Exit hole types

Figure 2

TP-6328 5/04

Acceptable Hardware Combinations

Appendix A-3

Appendix C General Torque Specifications Use the following torque specifications when service literature instructions give no specific torque values. The charts list values for new plated, zinc phosphate, or

oiled threads. Increase values by 15% for nonplated threads. All torque values are +0%/--10%.

American Standard Fasteners Torque Specifications

Size

Assembled into Aluminum Grade 2 or 5

Assembled into Cast Iron or Steel

Torque Measurement

Grade 2

Grade 5

Grade 8

8-32

Nm (in. lb.)

1.8

(16)

2.3

(20)

—

1.8

(16)

10-24

Nm (in. lb.)

2.9

(26)

3.6

(32)

—

2.9

(26)

10-32

Nm (in. lb.)

2.9

(26)

3.6

(32)

—

2.9

(26)

1/4-20

Nm (in. lb.)

6.8

(60)

10.8

(96)

14.9 (132)

6.8

(60)

1/4-28

Nm (in. lb.)

8.1

(72)

12.2 (108)

16.3 (144)

8.1

(72)

5/16-18

Nm (in. lb.)

13.6 (120)

21.7 (192)

29.8 (264)

13.6 (120)

5/16-24

Nm (in. lb.)

14.9 (132)

23.1 (204)

32.5 (288)

14.9 (132)

3/8-16

Nm (ft. lb.)

24.0

(18)

38.0

(28)

53.0

(39)

24.0

(18)

27.0

(20)

3/8-24

Nm (ft. lb.)

27.0

(20)

42.0

(31)

60.0

(44)

7/16-14

Nm (ft. lb.)

39.0

(29)

60.0

(44)

85.0

(63)

—

7/16-20

Nm (ft. lb.)

43.0

(32)

68.0

(50)

95.0

(70)

—

1/2-13

Nm (ft. lb.)

60.0

(44)

92.0

(68)

130.0

(96)

—

1/2-20

Nm (ft. lb.)

66.0

(49)

103.0

(76)

146.0 (108)

—

9/16-12

Nm (ft. lb.)

81.0

(60)

133.0

(98)

187.0 (138)

—

9/16-18

Nm (ft. lb.)

91.0

(67)

148.0 (109)

209.0 (154)

—

5/8-11

Nm (ft. lb.)

113.0

(83)

183.0 (135)

259.0 (191)

—

5/8-18

Nm (ft. lb.)

128.0

(94)

208.0 (153)

293.0 (216)

—

3/4-10

Nm (ft. lb.)

199.0 (147)

325.0 (240)

458.0 (338)

—

3/4-16

Nm (ft. lb.)

222.0 (164)

363.0 (268)

513.0 (378)

—

1-8

Nm (ft. lb.)

259.0 (191)

721.0 (532)

1109.0 (818)

—

1-12

Nm (ft. lb.)

283.0 (209)

789.0 (582)

1214.0 (895)

—

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.) Assembled into Cast Iron or Steel Size (mm)

A-4 Appendix

Grade 5.8

Grade 8.8

Grade 10.9

Assembled into Aluminum Grade 5.8 or 8.8

M6 x 1.00

5.6

(4)

9.9

(7)

14.0

(10)

5.6

(4)

M8 x 1.25

13.6

(10)

25.0

(18)

35.0

(26)

13.6 (10)

M8 x 1.00

21.0

(16)

25.0

(18)

35.0

(26)

21.0 (16)

M10 x 1.50

27.0

(20)

49.0

(35)

68.0

(50)

27.0 (20)

M10 x 1.25

39.0

(29)

49.0

(35)

68.0

(50)

39.0 (29)

M12 x 1.75

47.0

(35)

83.0

(61)

117.0

(86)

—

M12 x 1.50

65.0

(48)

88.0

(65)

125.0

(92)

—

M14 x 2.00

74.0

(55)

132.0

(97)

185.0 (136)

—

M14 x 1.50

100.0

(74)

140.0 (103)

192.0 (142)

—

M16 x 2.00

115.0

(85)

200.0 (148)

285.0 (210)

—

M16 x 1.50

141.0 (104)

210.0 (155)

295.0 (218)

—

M18 x 2.50

155.0 (114)

275.0 (203)

390.0 (288)

—

M18 x 1.50

196.0 (145)

305.0 (225)

425.0 (315)

—

TP-6328 5/04

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com

TP-6328 5/04 E 2004 by Kohler Co. All rights reserved.

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

Kohler 8.5 & 12RES Installation Manual - Apprep.com

Kohler 8.5 & 12RES Installation Manual - Apprep.com

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